Additive Manufacturing Processes
The Processes of AM
Additive manufacturing is the process of applying 3D-printing to industrial production, allowing materials to be created without joints and with minimal post-processing. Multiple materials can be used during this process, which makes it easy to create new products with minimal waste and lower materials costs.
There are several AM production techniques. Each varies due to materials, layering, and required machine technology. EWI specializes in all ASTM F42-compliant AM processes and can help your team identify, design, and implement the right solution for your application. Our process expertise includes:
- Powder Bed Fusion
- Directed Energy Deposition
- Binder Jetting
- Solid State Processes
Powder Bed Fusion
This type of additive manufacturing uses either a laser or electron beam to melt and fuse material powder together to develop products. Here are the differences between the two types of powder bed fusion :
- Laser Powder Bed Fusion – In laser powder bed fusion, a laser is used to heat material in a powder form into 3D products. After a layer of powder has been indexed down, a new layer of powder is spread to continue the process. Ultimately, laser powder bed fusion does not require support.
- Electron Beam Powder Bed Fusion – This type of powder bed fusion is used to melt particles together in specific areas. The beam can be manipulated very fast, which speeds the overall process by allowing multiple melt pools to occur simultaneously.
Directed Energy Deposition
In directed energy deposition (DED), powder or metal wire is used with an energy source to add material or fuse a material onto an existing part or to create a new part. The process is generally used in large-scale additive manufacturing. These are the three types of directed energy deposition:
- Laser DED – Laser DED deposits powder onto the build while being melted by the laser at the same time. This process can generate much faster build rates over conventional laser powder bed fusion.
- Arc DED (also known as wire arc additive manufacturing or WAAM) – This EWI specialty is more dynamic than other additive manufacturing processes. Arc DED is suitable for large builds. An advantage for manufacturers is that existing arc-welding robots and power supplies can be retrofitted for the process.
- Electron Beam DED – EB-DED enables the manufacturing of large parts extremely fast, which gives it an advantage over other types of additive manufacturing. The process is applied in industries such as heavy machinery, construction, mining, and aerospace to make large, low-volume parts.
Binder Jetting
Metal binder jetting additive manufacturing uses an ink-jet print head to print a binder onto the powder, which binds the metal particles together into a green state. The parts are then removed from the powder bed and must go through a debinding and sintering process in an oven to make the parts dense and hard. Parts typically shrink 20-25% during the sintering process.
Solid-State Processes
Solid-state additive manufacturing (SSAM) refers to 3D printing methods that join materials without melting them. These processes can eliminate issues typically associated with a liquid phase, like cracking or porosity. SSAM includes ultrasonic AM and cold spray processes – high pressure, low pressure, and laser assisted.
Additive Manufacturing Tooling & Process Services
Searching for additive manufacturing services? The team of experts at EWI is ready to identify the best AM processes to solve your challenge, develop the right engineering solution, and implement the new technology or processes. Give our team a call today at 614.484.7600 or submit a contact request.